Calling fox 40 owners, some tech help please!!!

Ok, here's the story... I have a yeti asx with a full dh kit on it. I also happen to have a fox 40. I'm lowered the 40 1 inch to 7 inches to change the frame geo a little. I did EXACTLY as the manual told me, put the correct ammount of oil in, and put the spacers where they should be.

Got it back together, went for a parking lot test, and around 1/2 way through the travel, I hear a clicking noise. I don't think it's the spacers, because it makes 2 clicks. Once when it goes through the travel, and once when its rebounding or coming out.

what it seems like is your spring is rubbing. take your top cap off, and flip the spring. Try that out. Sometimes, the shrink wrap slips down the spring, and since its not where it should be, the spring rubs away. First flip the spring, and try it out, if it still rubs, youll have to separate the shrinkwrap further apart, until you find where its rubbing and eliminate it.

And secondly, if the spring makes contact with the sanction one time, why is it making 2 clicks?

Thanks guys for your input, I really do appreciate it.

Click to expand...

Springs wear in a pattern, like everything else on a bike, Tires, Brakes Etc, so when you went back together the spring isnt sitting in the exact same spot, so now it loads just a touch. The wear is right at the very ends of the spring, and is the spring seats arent absolutly perfect, then you will tweak the spring ever so slightly to match the inperfection of the seat, so now that the spring is sitting in a different orientation, its loading just ever so differently, making it contact ever so slightly. Best bet is to pull the spring out, redo the shrinkwrap, and reinstall it.

This is something that is NOT just a fox happening, alot of long travel forks have the same issues when rebuilding them, Fox Marzocchi, Rockshox, Manitou Etc. I have done at three of each of the above listed Manf.. Same fix for all of them.